Hylsa Process

(HYL III and HYL-

4M)
K E LO M P O K 2
DIMAS REZA LAZUARDI - 1406532740
H A N I N D I T O H A I DA R S AT R I O - 1 4 0 6 5 3 2 7 2 1
M U H A M M A D FAT H U R RA H M A N - 1 4 0 6 5 3 2 7 9 1
P RA N AWA D W I P RA D I P TA - 1 4 0 6 5 3 2 7 3 4
RA I P RATA M A - 1 4 0 6 5 3 2 7 6 6
HYL PROSES
H Y L ATA U H Y L S A A D A L A H S U AT U P R O S E S R E D U K S I
LANGSUNG YA N G DITEMUKAN OLEH S E O RA N G
B E R K E B A N G S A A N M E X I C O B E R N A M A H OYA L A N TA .
HYL DIRECT REDUCTION PROSES (REDUKSI LANGSUNG)
ADAL AH HASIL USAHA RISET YA N G D I M U L A I O L E H
H O J A L ATA Y L . M I N A , S . A . , PA D A P E R M U L A A N TA H U N
1950-AN.
US A HA INI MUNCUL DA RI TEKANAN KEBU TUHAN UNTUK
H A R U S M E M P E R O L E H B A H A N B A K U YA N G C U K U P M U T U
D A N PA D A H A R G A YA N G S TA B I L U N T U K P R O D U K S I
L E M B A RA N B A J A ( S H E E T S T E E L ) .
History
Di Tahun 1957, setelah bertahun-tahun riset dan
pengembangan, Hylsa memulai pabrik (Direct
Reduction) reduksi langsung bijih besi sukses pertama
dunia. Teknologi ini menyediakan Besi murni untuk
pembuatan baja (steelmaking), meningkatkan mutu baja
dengan mengurangi unsur-unsur yang bersifat sisa atau
pengotor seperti S & P yang biasanya ditemukan di
dalam sisa baja ( steel scrap ).
HYL Plant 1M, Hylsa First HYL III Process
1957 - Monterrey Plant
(Hylsa 2M-5)
1980 - Monterrey,
Mexico
Input Output Process
Gas-based process
Input : pellet / lump ore (oxide)
Output : HBI / DRI or HDRI (sponge iron)
DRI berupa pellet atau lump ore
HBI compressed DRI
DRI on-site production and used in EAF
HBI commercial shipment
5000 tonnes per day
Input Output Process (Contd)
DRI (Direct Reduced Iron) :
Cold DRI, which is commonly used in adjacent meltshops close to the DR facilities.
It can also be shipped and exported, provided procedures are taken to avoid
reoxidation.
HBI (Hot Briquetted Iron) :
DRI which is hot discharged and briquetted, most commonly used for overseas
merchant and export.
HYTEMP iron:
Hot discharged DRI, pneumatically transported from the DR plant to the meltshop
for its direct feed in the EAF/BOF.
Raw Materials
Item Pellet Ore Lump
Fe 66.57% 66.50%
SiO2 2.25% 0.71%
Al2O3 0.28% 1.66%
P 0.017% 0.015%
S 0.011% 0.005%
CaO 2.10% -
MgO 0.08% -
HYL Process Reactor
Process (HYL III)
Two independent section : reducing gas generation and iron oxide reduction
Pre-heating gas to 930oC and pressurizing to 6 bar : natural gas stream mixed
with recycled gas from CO2 removal system
Quenching, dust removal and desulphurization, also compression of gas
Reduction of iron ore by H2
HYL III Flowsheet
HYL III Process (Contd)
HYL III Process (Contd)
HYL III Process (Contd)
HYL III Process (Contd)
Process (HYL4M)
Three main unit : reduction system, DRI handling system, external cooling
system
Pre heating charge : natural gas and recycled gas fed to humidifier to
control carbon deposition rate
Primary reduction : O2 injection increase temperature to 1020 oC
Cooling of reduced charge gas heated and used to primary reduction,
natural gas reformation
DRI discharge
Process (HYL4M)
Process Reactions
3Fe2O3 + H2 2Fe3O4 + H2O
3Fe2O3 + CO 2Fe3O4 + CO2
Fe3O4 + H2 3FeO + H2O
Fe3O4 + CO 3FeO + CO2
FeO + H2 Fe + H2O
FeO + CO Fe + CO2
Some DRI reacts with carbon Fe3C formation and excess free carbon
Products Specs
Item DRI HBI
Fe total (%) 90 - 91 90 91
Degree of metallization (%) 92 - 94 92 94
Carbon content (%) 1.5 2.5 1.0
Gangue (%) 3.5 4.0 3.5 4.0
Advantages and Disadvantages
of Process
Advantages :
Proven equipment performance (HYL4M developed from HYL II and HYL III)
No reformer lower capital cost (HYL4M)
Gas-based operation offers alternative cheaper reductant lowers cost
Raw material flexibility high S ore and natural gas (HYL III)
References
Greene, Lockwood. (2000). Ironmaking Process Alternatives Screening Study
Vol. 1 : Summary Report. Departement of Energy, United States of America.
Greene, Lockwood. (2000). Ironmaking Process Alternatives Screening Study
Vol. 2 : Appendix. Departement of Energy, United States of America.
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